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General Provisions (00100-00999)

615if there is a conflict between Section 615 and AASHTO/N SBA S2.1

DE · 2025 Standard SpecificationsBook pages 279294View official source ↗

STEEL STRUCTURES SECTION 615 269 1. Perform all fabrication of bridge members in accordance with AASHTO/NSBA Steel Bridge Collaboration S2.1Steel Bridge Fabrication Guide. Where AASHTO/NSBA refer to AASHTO LRFD Bridge Design Specifications or AASHTO LRFD Bridge Construction Specifications , use the version identified in the plans.

2.Requirements of Section 615 are in addition to AASHTO/NSBA S2.1. Follow the requirement in
3.Follow all applicable provisions of the appropriate version of ANSI/AWS D1.5. Refer to

ANSI/AWS D1.3 Structural Welding Code – Sheet Steel when welding sheet steel thinner than 1/8-inch.

4.Give at least 7 days notice before commencing fabrication work. Include a schedule for all major

fabrication processes and dates when inspections are to occur. Perform no work in the plant before the engineer authorizes fabrication. Pay the Department’s travel costs when changes to the contractor’s fabrication or inspection schedules are not adequately conveyed to the Department.

5.Material identification.
a.Assembly -mark individual pieces and issue cutting instructions to the shop using a system that

will maintain identity of the original piece.

b.Identify structural steel by standard and grade of steel. Also differentiate between material

toughness requirements (CVN, fracture -critical) as well as any other special physical requirements. In addition, identify structural steel for primary members by mill identification numbers (heat numbers). Use an approved identification system. Use either paint or low - stress stencils to make identification markings on the metal. Mark the material as soon as it enters the shop and carry the markings on all pieces through final fabrication. Transfer the markings before cutting steel for primary members of bridge structures into smaller pieces. Loss of identification marking on any piece, with no other positive identification, or loss of heat number identification o n any primary member piece will render the piece unacceptable for use.

6.Welding.
a.Trim plates with rolled edges used for webs by thermal cutting.
b.Use weld tabs at least 2 -inches long for manual and semi -automatic processes, at least 3 -

inches long for automatic processes, and in all cases at least as long as the thickness of the material being welded. Use longer weld tabs as required for satisfactory work.

c.Terminate fillet welds approximately 1/4 -inch from the end of the attachment except for

galvanized structures and flange -to-web welds, for which the fillet weld must run the full length of the attachment, unless otherwise shown on the plans.

d.Keep surfaces within 4 -inches of groove welds or within 2 -inches of fillet welds free from shop

paint.

e.For galvanized assemblies, completely seal all edges of tightly contacting surfaces by welding

before galvanizing.

f.Do not use hand -held semiautomatic submerged -arc welding (SAW) for welding bridge

members unless altered to provide automatic guidance or otherwise approved. STEEL STRUCTURES SECTION 615 270 g. Keep at least 6 -inches between shop splices and stiffeners or cross -frames. Obtain approval for shop splices added after shop drawings are approved.

h.For splice welds, grind shop groove welds in flange plates smooth and flush with the base

metal on all surfaces whether the joined parts are of equal or unequal thickness. Grind so the finished grinding marks run in the direction of stress, and keep the metal below the blue brittle range (below 350 degrees F). Groove welds in web plates, except at locations of intersecting welds, need not be ground unless shown on the plans except as required to meet the appropriate version of the ANSI/AWS welding code r equirements.

i.Never restrain a joint on both sides when welding.
j.Stiffener Installation.
i.Members must meet combined tilt and warpage tolerances before the installation of

stiffeners. ii. Cut stiffeners to fit acceptable flange tilt and cupping. The engineer will permit minor jacking or hammering that does not permanently deform the material. iii. Tack weld intermediate stiffeners within 12 -inches of a welded field splice point in the shop. Weld the stiffeners in the field in accordance with the appropriate version of the ANSI/AWS welding code after the splice is made.

k.Perform magnetic particle testing (MT), radiographic testing (RT), or ultrasonic testing (UT) as

specified in D1.5 for bridge structures. The engineer will periodically witness, examine, verify, and interpret NDT. Additional welds may be designated for NDT on the plans. Retest repaired groove welds per the applicable ANSI/AWS code after repairs are made and have cooled to ambient temperature. Complete N DT and repairs before assembly of parts into a member, but after any heat -correction of weld distortion .

i.Radiographs must have a density of at least 2.5 and no more than 3.5, as a radiographer

confirms. The density in any single radiograph showing a continuous area of constant thickness must not vary in this area by more than 0.5. Use only ASTM System Class I radiographic film as described in ASTM E1815. Use low -stress stencils to make radiograph location identification marks on the steel. ii. Have UT equipment calibrated yearly by an authorized representative of the equipment manufacturer or by an approved testing laboratory. iii. Use half -wave rectified DC when using the yoke method unless otherwise approved. Welds may be further evaluated with the prod method for detecting centerline cracking.

l.If problems develop during galvanizing of welded material, the engineer may require a test of

the compatibility of the combined galvanizing and welding procedures in accordance with this section and may require modification of 1 or both of the galvanizing and welding procedures.

i.Prepare a test specimen with a minimum length of 12 -inches using the same base material,

with the same joint configuration, and using the welding procedure proposed for production work if testing is required. Clean and galvanize this test specimen using the same conditions and procedure that will be applied to the production galvanizing. ii. Examine the test specimen after galvanizing. There must be no evidence of excessive buildup of zinc coating over the weld area. Excessive zinc coating buildup will require modification of the galvanizing procedure. STEEL STRUCTURES SECTION 615 271 iii. Remove the zinc from the weld area of the test specimen and visually examine the surface. There must be no evidence of loss of weld metal or any deterioration of the base metal due to the galvanizing or welding procedure. Modify the galvanizing or wel ding procedure as required if there is evidence of deterioration or loss of weld metal, and run a satisfactory retest on the modified procedures before production work. Report procedures and results on the galvanized weldment worksheet provided by the Depa rtment.

7.Prepped and painted in accordance with Section 616.
8.Store structural steel, plain or fabricated, above the ground on platforms, skids, or other

supports. Keep steel free from dirt, grease, and other matter, and protect it from corrosion. Store high -strength fasteners as specified in Section 615.3.C.8.a.

9.Plates.
a.Cut and fabricate steel plates for main members and splice plates for flanges and main tension

members so the primary direction of rolling remains parallel to the main tensile and compressive stresses.

b.Plane, mill, grind, or thermal -cut to a depth of 1/4 -inch the sheared edges of plates more than

5/8-inch thick that carry calculated stress.

i.Perform oxygen cutting in accordance with AASHTO/AWS D1.5 bridge welding code.

ii. Perform visual inspection and repair of plate -cut edges in accordance with AASHTO/AWS D1.5 bridge welding code.

c.For bent plates, adhere to the requirements of Section 11.4.3.3 of AASHTO LRFD Bridge

Construction Specifications.

10.Mill or grind bearing ends of bearing and jacking stiffeners to provide the fit specified in the

applicable version of ANSI/AWS D1.5.

11.Ensure intermediate stiffeners fit tightly against the compression flange. Ensure the surface

finish for bearing, base plates, and other bearing surfaces that contact each other or concrete are in accordance with Table 615.3 -1. Table 615.3 -1. ANSI Surface Roughness Values Bearing Surface in. × 10-6 Steel slabs 2,000 Heavy plates in contact in welded shoes 1,000 Milled ends of compression members, milled or ground ends of stiffeners and fillers 500 Bridge rollers and rockers 250 Pins and pin holes 125 Sliding bearings 125

12.Member tolerances.
a.Provide dimensional tolerances as follows:

STEEL STRUCTURES SECTION 615 272 i. Rolled shapes, plates, bars, wide -flange sections, and miscellaneous steel in accordance with ASTM A6; ii. fabricate girders in accordance with the AASHTO/AWS D1.5, Bridge Welding Code and as described below; and iii. refer to AASHTO/AWS D1.5, bridge welding code, for tolerances for camber and sweep of continuous and simply supported girders of any shape. The camber and sweep tolerances for steel pier caps are the same as those specified for girders. Measure sweep for horizontally curved members from the theoretical centerline for comparison to the aforementioned requirements. In anticipation of uneven shrinkage, adjust camber ordinates accordingly.

b.If measuring girder length with a device that is free of thermal effects, adjust the

measurements accordingly. All dimensions given are based on an ambient temperature of 68 degrees F. Measure the length of horizontally curved girders along the arc.

13.Straighten plates, angles, other shapes, and built -up members without fracturing or damaging

the metal. Perform heat -straightening of AASHTO M270 Grades 70W, 100, and 100W steel members only under rigidly controlled conditions, subject to approval of t he engineer. Do not exceed the temperature values specified in Table 615.3 -2. Table 615.3 -2. Maximum Straightening Temperature Material to Be Straightened Maximum Temperature (°F) Grade 70W > 6 in ches from weld 1,050 Grade 70W < 6 in ches from weld 900 Grade 100 and 100W > 6 in ches from weld 1,100 Grade 100 and 100W < 6 in ches from weld 950

a.The maximum straightening temperature for all other steels is 1,200 degrees F. Measure

temperature using temperature -indicating crayons, liquids, or bimetal thermometers. The engineer will reject material heated in excess of the specified limits unless testing verifies material integrity.

b.Ensure parts to be heat -straightened are free of stress and external forces, including stresses

from mechanical means used to apply the heat.

c.The engineer will reject all straightened pieces showing evidence of fracture.
d.Make sharp corners into round edges by grinding for exposed edges of painted steel.
14.Heat curving.
a.Heat -curving of beams and girders can occur when the horizontal radius of curvature

measured to the centerline of the member web is greater than both values calculated by Equations 1 and 2 below, and greater than 150 -feet at any and all cross sections throughout the length of the member. Do not heat -curve steels manufactured to a yield strength greater than 50 kips per square inch, other than AASHTO M270, Grade HPS 70W. STEEL STRUCTURES SECTION 615 273

b.In addition to the above requirements, do not heat -curve if the radius is less than 1,000 -feet

when the flange thickness exceeds 3 -inches, or the flange width exceeds 30 -inches.

c.Curve beams and girders by either continuous or V -type heating. For the continuous method,

heat a strip or intermittent strips along the edge of the top and bottom flange simultaneously. Ensure the strip has sufficient width and temperature to obtain th e required curvature.

d.Conduct heat -curving operations at temperatures less than 1,150 degrees F. Do not artificially

cool the girder until it has naturally cooled to 600 degrees F. Obtain approval for the method of artificial cooling.

e.Heat -curve the girder with the web in either a vertical or a horizontal position. When curved in

the vertical position, brace or support the girder to prevent lateral deflection and keep the girder from overturning.

15.When curved in the horizontal position, support the girder near its ends and at intermediate

points to obtain a uniform curvature. When the girder is positioned horizontally for heating, maintain intermediate safety catch blocks at the mid -length of th e girder within 2 -inches of the flanges at all times during the heating process to guard against a sudden sag resulting from plastic flange buckling.

16.Bolt Holes for high -strength bolts and unfinished bolts:
a.Punch or drill bolt holes as follows:
i.Either sub -drill and ream, sub -punch and ream, or drill full -size holes. The standard hole size

is the bolt diameter plus 1/16 -inch. ii. Full-size holes may be drilled or punched in unassembled pieces using computer numerically controlled (CNC) drilling or punching equipment. Holes punched full -size shall meet Article 11.4.8.1 of the specified edition of AASHTO LRFD Bridge Construction Specifications.

(1)Holes drilled or punched full -size using CNC equipment may be drilled or punched either

through individual unassembled pieces or drilled fill -size through any combination of pieces held together.

STEEL STRUCTURES SECTION 615 274 (2) Demonstrate the accuracy of the drilling or punching procedures by means of a check assembly of the primary load -carrying components of the structure. iii. When specified, sub -punch or sub -drill all holes 1/4 -inch smaller than the final hole diameter. Sub -drill if thickness limitation governs. After assembling, ream or drill to full size. iv. When specified, the contractor may use enlarged or slotted holes for high -strength bolts.

b.For punched holes, ensure that the die diameter does not exceed the punch diameter by more

than 1/16 -inch. Ream undersized holes. Ensure holes are clean -cut, without torn or ragged edges.

c.For drilled holes, either sub -drill and ream or drill full -size holes perpendicular to the member

to meet the above size requirements. Where practical, use mechanically directed reamers. Remove burrs on the outside surfaces. Ream and drill using twist d rills, twist reamers, or roto - broach cutters. Assemble and securely hold connecting members while reaming or drilling holes. Match -mark before disassembling.

d.Use steel templates that have hardened steel bushings in the holes and have accurate

dimensions from the connecting centerlines as inscribed on the template. Use the centerlines to locate the template from the milled or scribed ends of the members.

e.Hole Tolerances:
i.Individual hole.
(1)Acceptable holes are those not more than 1/32 -inch larger in diameter than the decimal

equivalent of the minimal diameter resulting from the drill or reamer. For slotted holes, ensure the slotted -hole width produced by flame -cutting or a combination of drilling or punching and flame -cutting is no more than 1/32 -inch larger than the nominal width. Grind the flame -cut surface smooth. ii. Hole group.

(1)Before reaming, punch full -sized, sub -punched, or sub -drilled holes so that, after assembling

and before any reaming occurs, it is possible to insert a cylindrical pin into the member, 1/8 - inch smaller in diameter than the nominal size of the punched h ole, without drifting, in at least 75 percent of the contiguous holes in the same plane. The engineer will reject pieces not meeting this requirement. The engineer will also reject holes not large enough to pass a pin that is 1/4 -inch smaller than the nomi nal size of the punched hole.

(2)Ensure that, when reaming or drilling holes, 85 percent of the holes in any contiguous group

show no offset greater than 1/32 -inch between adjacent pieces. iii. For ribbed bolts, turned bolts, or other approved bearing -type bolts, sub -punch or sub -drill holes 3/16 -inch smaller than the nominal bolt diameter. Ream when assembled, or drill using a steel template or, once assembled, drill from the solid to ensur e the finished holes provide a driving fit.

17.Clean and coat fabricated work in accordance with Section 616.
C.Assembly :
1.For bolted connections, prepare contact surfaces in accordance with Section 616 before

assembling. Remove all burrs and shavings, and ensure the member is free from twists, bends, and other deformations. STEEL STRUCTURES SECTION 615 275 a. When assembling, allow enough drifting to bring the parts into position. Do not allow the drifting to enlarge the holes or distort the metal.

b.Install bolts with bolt heads on the bottom of bottom flanges and the exterior face of exterior

girders.

2.Prepare edges according to AASHTO/AWS D1.5 Bridge Welding Code.
3.As required in Section 615.3.B.16, verify the accuracy of CNC drilling or punching procedures by

means of a check assembly of the primary load carrying components of the structure including stringers, plate girders, tub girders, trusses, and cross -frames or diaphragms of curved and skewed bridges. Verify the camber, alignment, and accuracy of holes in the check assembly. If the check assembly fails in any of these areas, further check assemblies may be required by the Department. Use a minimum of 3 conti guous field sections for the check assembly.

a.For trusses, use 3 contiguous truss panels.
b.For projects with only 2 contiguous field sections, use both sections.
c.Progressive check assemblies are permitted provided that 3 contiguous sections are in

assembly at all times and 1 section is removed from the assembly as a new section is added.

4.Prepare holes for bolted connections as specified in Section 615.3.C.16. Where applicable,

assemble major components with milled ends of compression members in full bearing and then ream the sub -sized holes to the specified size while assembling the con nections.

5.Before performing field -welded connections, prepare or verify the fit of members including the

proper space between abutting flanges with the segment preassembled.

6.When specified, provide unfinished or turned bolts conforming to ASTM A307, Grade A bolts.

Provide bolts with single, self -locking nuts or double nuts, unless otherwise specified. Use beveled washers where bearing faces have a slope of more than 1:20 wi th respect to a plane normal to the bolt axis.

a.Provide unfinished bolts unless otherwise specified.
b.When specified, provide turned bolts with an ANSI roughness rating value of 125 for the

surface of the body of the bolts. Ream turned bolt holes and turn the bolt to a driving fit with the threads entirely outside of the holes. Use hexagonal -headed bolts and nuts, and provide washers.

7.For connections using high -strength bolts, use ASTM F3125 high -strength bolts, or equivalent

fasteners, installed to develop the minimum required bolt tension specified in Table 615.3 -5. Install bolts in holes formed as specified in Section 615.3.C.16. When using turn -of-nut tightening method, provide hardened washers under the element turned in tightening.

a.For bolted parts, use steel for all material within the grip of the bolt. Do not use compressible

material such as gaskets or insulation within the grip. Ensure that bolted steel parts fit solidly together after tightening the bolts. Limit the maximums lope to 1:20 for the surface parts in contact with the bolt head or nut, with respect to a plane normal to the bolt axis.

b.At the time of assembly, ensure that all joint surfaces, including surfaces adjacent to the bolt

head and nut, are free of scale, except tight mill scale, and free of dirt or other material. Remove burrs and any other material that would prevent solids eating of the connected parts in the snug condition. STEEL STRUCTURES SECTION 615 276 c. Paint the faying surface as designated in the AASHTO LRFD Bridge Design Specifications.

d.Meet the following requirements , as applicable, for the faying surfaces:
i.Blast -clean and coat in accordance with Section 616.

ii. Assemble after the coating has cured for the minimum time used in the qualifying test.

8.Bolts and fasteners:
a.Hot-dip galvanize faying surfaces of fastener assemblies in accordance with AASHTO M111.

Assemble and assign lot numbers before shipping. Protect faying surfaces from dirt and moisture. Remove from protective storage only the number of assemblies planne d for installation and tensioning during a work shift. Return unused assemblies to protected storage at the end of the shift. Do not clean assemblies or remove manufacturer -applied lubricant as - delivered unless instructed by the manufacturer. Clean assembl ies for slip -critical connections that accumulate rust or dirt resulting from job site conditions. Clean, re -lubricate, and test for rotational capacity before installation. Lubricate galvanized nuts with a lubricator containing a visible dye. Ensure plain bolts are oily to touch when delivered and installed. Remove lubricant on exposed surfaces before painting.

b.Provide a bolt -tension measuring device, meeting ASTM F 959, to perform the rotational

capacity test and to confirm the ability to satisfy the requirements of Table 615.3 -3. If approved, the contractor may use alternative design direct tension indicators (DTI) devices, provided the devices meet the above requirements or approved manufacturer specifications.

c.For short -grip bolts, the contractor may use DTIs with solid plates to perform the calibrated -

wrench verification test instead of a tension - measuring device. Verify the DTI lot first with a longer -grip bolt in the tension measuring device. The Departme nt will specify the test frequency. Calibrate the device annually.

d.Inspect and tension bolt, nut, and washer assemblies to the minimum tension specified in

Table 615.3 -3. Use impact wrenches to tension each bolt in approximately 10 -seconds. Table 615.3 -3. Minimum Required ASTM F3125 Bolt Tension (U.S. Customary Units) Bolt Diameter

(inch)Grade 325
(pound)Grade 490

(pound) 1/2 12,000 15,000 5/8 19,000 24,000 3/4 28,000 35,000 7/8 39,000 49,000 1 51,000 64,000 1 1/8 64,000 80,000 1 1/4 81,000 102,000 1 3/8 97,000 121,000 1 1/2 118,000 148,000 STEEL STRUCTURES SECTION 615 277 e. Do not reuse Grade 490 fasteners or galvanized Grade 325 fasteners. The contractor may reuse ungalvanized Grade 325 bolts, if approved. Table 615.3 -4. Nut Rotation from the Snug Condition Geometry of Outer Faces of Bolted Parts Bolt length measured from underside of head to end of bolt Both faces normal to bolt axis. One face normal to bolt axis and other face sloped not more than 1:20. Bevel washer not used. Both faces sloped not more than 1:20 from normal to bolt axis. Bevel washers not used. ≤ 4 diameters 1/3 turn 1/2 turn 2/3 turn > 4 diameters, but ≤ 8 diameters 1/2 turn 2/3 turn 5/6 turn > 8 diameters, but ≤ 12 diameters 2/3 turn 5/6 turn 1 turn

f.Install bolts in all holes of the connection and bring the connection to a snug condition.
g.Snug systematically from the most rigid part of the connection to the free edges. Repeat until

the full connection is in a snug condition.

h.The minimum required bolt tension is 70 percent of the specified minimum tensile strength of

bolts rounded to the nearest 1,000 -pounds. Refer to ASTM specifications for tests of full -size A325 and A490 bolts, loaded in axial tension.

i.For situations in which the bolt length measured from the underside of the head to the end of

the bolt exceeds 12 diameters, determine the required rotation by tests in a suitable tension device simulating the actual conditions.

j.Perform tests for all fastener assemblies. Include washers as part of the test even if not

required as part of the installation procedure. If members are galvanized, test for rotational capacity after galvanizing process.

k.Perform the rotational capacity test in accordance with ASTM A325 and test each combination

of bolt production lot, nut lot, and washer lot as an assembly. The contractor does not have to include washers not required by the installation procedures in the lot identification. Assign a rotational capacity lot number to each combination of lots tested. Test a minimum of 2 assemblies per rotational capacity lot.

l.For bolts long enough to fit in a Skidmore -Wilhelm Calibrator, assemble the bolt, nut, and

washer assembly in this device or an acceptable equivalent.

m.Ensure the torque necessary to produce the required fastener tension does not exceed the

value obtained by the following equation: Torque ≤ 0.25PD where: Torque = measured torque (foot -pounds) P = measured bolt tension (pounds) D = bolt diameter (foot)

n.Test bolts too short to test in a Skidmore -Wilhelm Calibrator in a steel joint. Do not apply the

tension requirement specified above. Instead, compute the maximum torque requirement, STEEL STRUCTURES SECTION 615 278 0.25PD, using a value of P equal to the turn test tension taken as 1.15 times the bolt tension specified in Table 615.3 -3.

o.Use a hardened beveled washer to compensate for the lack of parallelism where the outer

face of the bolted parts has a slope greater than 1:20 with respect to a plane normal to the bolt axis.

i.Ensure that square or rectangular hardened beveled washers for American Standard Beams

and Channels meet ASTM F436 and taper in thickness. ii. Hardened washers are not required for connections using ASTM F3125, Grade 325 bolts except as follows:

p.Use hardened washers under the element turned when tightening using the calibrated wrench

method.

i.Hardened steel washers are required as part of rotational -capacity tests, even if the washers

are not required in the actual installation. ii. When installing ASTM F3125, Grade 490 bolts in material having a specified minimum yield strength less than 50 kips per square inch, irrespective of the tightening method. iii. When installing ASTM F3125, Grade 490 bolts, over 1 -inch in diameter, in an oversize or short slotted hole in an outer -ply. In these cases, use a 5/16 -inch minimum thickness washer under both the head and the nut. Do not use multiple hardened washers stacked upon one another. iv. When installing ASTM F3125, Grade 325 bolts in a long slotted hole in an outer ply, provide a plate washer or continuous bar of at least 5/16 -inch thickness with standard holes. Provide washers or bars of sufficient size to completely cover the slot af ter installation. Use a single hardened washer conforming to ASTM F436, but with a minimum thickness of 5/16 -inch, or use a washer or bar of structural grade material. Do not use multiple hardened washers to achieve a thickness of 5/16 -inch.

q.For the turn of the nut installation method, hardened washers are not required except as

specified in Section 615.3.C.8.I.

i.Check a representative sample of no fewer than 3 bolt and nut assemblies of each diameter,

length, and grade used in the work. Use a device capable off indicating bolt tension. Demonstrate that the method used by the bolting crew to develop a snug condition, and to control the turns, develops a tension of no less than 5 percent greater than the tension required by Table 615.3 -3. Retest as required. ii. Following the snug -tightening operation, tension bolts in the connection by the amount of rotation specified in Table 615.3 -4. During the tensioning operation, ensure that there is no rotation of the part not turned by the wrench. Tension systematically from the most rigid part of the joint to the free edges.

r.Use the calibrated wrench installation method only when calibration of wrenches takes place

on a daily basis, and when using a hardened washer under the turned element. Use standard torques, determined from tables or from formulas.

s.When using calibrated wrenches for installation, set the wrenches to deliver a torque

calibrated to produce a tension of no less than 5 percent in excess of the minimum tension, specified in Table 615.3 -3. Calibrate the installation procedures by verification testing at least STEEL STRUCTURES SECTION 615 279 once each working day for each fastener assembly lot installed that day. Verify by testing 3 typical fastener assemblies from each lot, in a tension -measuring device capable of indicating actual bolt tension. Sample bolts, nuts, and washers under the turne d element from production lots. Recalibrate wrenches when a significant difference occurs in the surface condition of the bolts, threads, nuts, or washers. Verify during installation in the assembled steel work that the wrench adjustment selected by the ca libration does not produce a nut or bolt head rotation from snug condition greater than that allowed in Table 615.3 -4. For manual torque wrenches, measure while nuts become torqued in the tensioning direction.

t.When using calibrated wrenches to install and tension bolts in a connection, install bolts with

hardened washers under the turned element. Snug and then tension the connection using the calibrated wrench. Tension systematically from the most rigid part of the joint to its free edges. Return the wrench to touch up previously torqued bolts that may have relaxe d as a result of the subsequent tensioning of adjacent bolts. Continue until all bolts become tensioned as required.

u.When tightening of bolts using DTI devices, assemble a representative sample of not less than

3 devices, for each diameter and grade of fastener used in the work, in a calibration device capable of indicating bolt tension. Include flat -hardened washers in the test assembly, if required in the actual connection, arranged as those in the actual pre -tensioned connections. Use the calibration test to demonstrate that the device indicates a tension no less than 5 percent greater than that specified in Table 6 15.3 -3. When installing bolts using DTI conforming to the requirements of ASTM F959, install bolts in all holes of the connection and bring to snug tight conditions. Indication of snug tight appears by partial compression of the direct tension indicator protrusions. Provide a maximum gap of 0.005 -inch after installation. Tighten all fasteners, progressing systematically from the most rigid part of the connection to the free edges, in a manner that minimizes relaxation of previously tightened fasteners.

v.In the presence of the engineer, inspect tightened bolts using a calibrated torque wrench,

unless using alternate fasteners or DTI that allow verification by other methods. Conduct the inspection before a loss of lubrication or corrosion influences the tightening torque.

w.Place 3 fastener assembly lots in the same condition as those under inspection in a device

calibrated to measure bolt tension. Conduct this calibration operation at least once each inspection day. Use a washer under the turned element in tensioning each bolt if washers used on the structure. If not using washers, ensure that the material used in the tension - measuring device abutting the part turned is of the same specification as that used on the structure. In the calibrated device, tension each bolt to the specified tension. Apply the inspecting wrench to the tensioned bolt to determine the torque required to turn the nut or head 5 degrees or approximately 1 -inch at a 12 -inch radius, in the tensioning direction. The inspection torque required for the work is the average of the torque required for all 3 bolts.

x.Randomly select 10 percent, or at least 2 bolts , of the tensioned bolts in each connection.

Apply the job inspection torque to each selected bolt with the inspecting wrench turned in the tensioning direction. If this torque turns no bolt head or nut, consider the bolts in this connection properly tensioned. If the torque turns 1 or more bolt heads or nuts, apply the job inspection torque to all bolts in the connection. Re -torque and re -inspect any bolt where a head or nut turns. STEEL STRUCTURES SECTION 615 280 9. Ensure that welding, welder qualifications, and prequalification of weld details and inspection of welds are in accordance with AASHTO/AWS D1.5 Bridge Welding Code. Do not weld or tack brackets, clips, shipping devices, or other material to any member not required, unless specified.

D.Erection :
1.Construct falsework and forms in accordance with Section 604.
2.Store material on skids. Keep storage area clean and properly drained. Store girders and beams

upright. Support long members to prevent damage from deflection.

3.Provide bearings and anchorages in accordance with Section 623. Verify dimensions and

elevations before ordering superstructure materials for staged construction projects.

4.Follow the erection procedures as detailed in the submitted erection drawings. Prepare and

submit revised erection drawings detailing all proposed deviations. Recalculate and submit erection stresses that differ from the planned method. Document changes in stresses or in behavior for the temporary and final structures. Provide additional material required to keep both the temporary and final stresses within the allowable limits used in design.

5.Provide temporary bracing or stiffening devices to accommodate handling stresses in individual

members or segments of the structure during erection.

6.Support segments of the structure to produce the proper alignment and camber in the

completed structure. Install cross frames and diagonal bracing to provide stability and ensure correct geometry. Provide all required temporary bracing.

7.Assemble using match marks. Ensure parts have no damage or distortion. Clean bearing

surfaces, and surfaces planned for permanent contact, before assembly. Fill a minimum 1/2 of the holes in splices and field connections, using equal numbers of bolts an d cylindrical erection pins, before installing and tightening the balance of high -strength bolts. Fill 3/4 of the holes in splices and connections carrying traffic during erection.

8.Use fitting -up bolts that have the same high -strength bolts used in the installation. If required to

use other fitting -up bolts, use the same nominal diameter as the high -strength bolts. Use cylindrical erection pins 1/32 -inch larger than the bolts.

9.Provide pilot and driving nuts in driving pins. Drive pins to take full bearing. Tighten pin nuts and

burr the thread at the face of the nut with a pointed tool.

10.Correct minor misfits by a minor amount of reaming, cutting, grinding, and chipping. Errors in

shop fabrication, or deformation resulting from handling and transporting, will result in rejection.

a.Steel structures repair:
i.Replace rivets or bolts with high strength bolts at locations identified in the contract.

ii. When replacing a group of rivets or bolts, remove 1 rivet at a time and immediately replace with a high -strength bolt before removal of the next rivet or bolt.

11.Ensure that welding removal and repair, welder qualifications, and prequalification of weld

details and inspection of welds in accordance with AASHTO/AWS D1.5 Bridge Welding Code. STEEL STRUCTURES SECTION 615 281 12. For heat straightening damaged steel girders, brace the damaged girders sufficiently to control movements occurring during stress relief. Erect work platforms from the ground. Do not attach work platforms to the superstructure.

a.Incorporate high heat input into the localized areas of the steel, with a minimum amount of

heat spread into the surrounding material. Use an approximately 1 -inch diameter, #3, multi - orifice Rosebud heating torch operating on approximately 25 PSI MAPP a nd 125 PSI oxygen. Do not use smaller or larger torches. Obtain approval of the equipment from the engineer before using a torch.

b.Confine heating to the patterns described here. Conduct heating such that the desired steel

location becomes heated to between 1,000 and 1,100 degrees F, as rapidly as possible, without overheating. Any heating procedures that heat any location on the girder to a temperature greater than 1,200 degrees F results in destructive heating. Repair or replace steel damaged by overheating.

c.Confine heating patterns to the areas required to bring the member back to its original

position. The engineer will approve the heat pattern location areas in the field before the beginning of the process.

d.During heating operations, to measure the heat intensity, provide and use temperature

indicating crayons manufactured for 600, 1,000, 1,100, 1,200, and 1,250 degrees F temperature limits.

e.Do not quench with water, or water and air. Perform cooling with dry compressed air after the

steel has cooled to 600 degrees F.

f.After removing the beam deformation, to the engineer’s satisfaction, clean and paint the

entire surface area indicated in the contract in accordance with Section 616. Match the paint color of the steel beam under repair to the color of the existing pain t.

615.4Method of Measurement.

A.The Department will measure work acceptably completed in accordance with Section 109.1 and as

follows:

B.The Department will compute pay quantities for each type of steel and iron from working

drawings using Table 615.4 -1: Table 615.4 -1. Mass Densities of Steel and Iron Material Mass Density lb/ft3 Cast Iron 445 Malleable Iron 470 Wrought Iron 487 Steel -rolled or cast 490

C.The Department will compute the weight of rolled shapes on the basis of nominal weight per foot

as specified, or listed in AISC manual of steel construction. STEEL STRUCTURES SECTION 615 282 D. The Department will compute the weight of castings from the dimensions shown on the approved shop drawings, deducting for open holes. The engineer may substitute scale weight for computed weight in the case of castings or of small complex parts.

E.The Department will exclude the weight of temporary erection bolts, shop and field paint, boxes,

crates, and other containers used for shipping, and materials used to support members during transportation and erection from then weight measurements. The mea surement will also exclude the weight of any additional material required to accommodate erection stresses resulting from the contractor’s choice of erection methods.

F.The measurement will make no allowances for the weight of paint or galvanizing.
G.The Department will measure all metal parts other than metal reinforcement for concrete unless

otherwise stipulated.

H.The Department will compute pay weight on the basis of computed net weight using 1 of the

following:

1.The Department will compute the weight on the basis of the net finished dimensions of the

parts as specified, deducting for copes, cuts, clips, and all open holes, except bolt holes.

2.The Department’s measurement will include the weight of heads, nuts, single washers, and all

high tensile strength bolts, both shop and field, on the basis of the specified edition of the AISC manual of steel construction.

I.The Department’s measurement will include the weight of fillet welds as specified in Table 615.4 -

2: Table 615.4 -2. Department’s Measurement of the Weight of Fillet Weld by Size in Inches. Fillet Weld

(inch)(Weight

lb/ft) 3/16 0.08 1/4 0.14 5/16 0.22 3/8 0.30 1/2 0.55 5/8 0.80 3/4 1.10 7/8 1.49 1 2.00

615.5Basis of Payment.

A.Price and payment for shop painting of new steel is incidental to the applicable steel structures

item and will constitute full compensation for:

1.Providing shop drawings;

STEEL STRUCTURES SECTION 615 283 2. all submittals;

3.contractor’s alternate designs;
4.fabrication;
5.storing;
6.transporting;
7.assembly;
8.hardware;
9.repairs;
10.repainting and surface preparation;
11.providing all materials;
12.providing protection against damage during paint application;
13.re-establishing project standards, if necessary;
14.re-cleaning when the contractor does not apply primer within 8 hours of initial cleaning; and
15.re-cleaning and repainting surfaces after use of unauthorized solvents, after application of paint

containing thinners after applying paint to contaminated surfaces, and after applying paint contrary to the requirements of this section.

B.Such payment is full compensation for providing all materials, equipment, labor, and all

incidentals required to complete the work as specified.

C.The Department will not pay for additional check assemblies when failing any of the check

assembly verifications. ITEM DESCRIPTION UNIT 615000 STEEL STRUCTURES LB 615001 STEEL STRUCTURES LS 615002 STEEL STRUCTURES (UNPAINTED) LB 615003 STEEL STRUCTURES (UNPAINTED) LS 615004 REPLACING STEEL RIVETS/BOLTS EACH 615005 STEEL STRUCTURE REPAIR LB 615006 STEEL STRUCTURE REPAIR LS 615007 WELDING REPAIR LF

STEEL SIGN STRUCTURES SECTION 617 284 SECTION 616 — STEEL COATINGS

616.1Description.

This work consists of providing and applying coating systems for structural steel .

616.2Materials.

A.Provide paint systems for coating structural steel that are Northeast Protective Coating

Committee (NEPCOAT) -approved and listed on the NEPCOAT Qualified Products List (QPL). Only products on the NEPCOAT QPL that have successfully tested below the VOC limi ts of 340 g/l for the organic zinc rich primer coat and below 250 g/l for the intermediate and top coats may be used. Use the appropriate paint type for the application as follows:

1.Use a paint system from NEPCOAT Qualified Products List A for shop -painted ne w structural

steel.

2.Use a paint system from NEPCOAT Qualified Products List B for existing painted structural steel.
3.Use a different color for each coat (i.e., primer, intermediate, and finish coat). The color of the

primer and intermediate coat can be the contractor’s option but must provide contrast with the underlying substrate or previously applied paint. Use a stripe coat of a different color. Ensure that all coats are from one paint system from one manufacturer.

4.Use a finish coat color that matches chip number 25183 (cyan -blue) of AMS -STD-595A for all

structural steel unless otherwise specified in the contract.

5.Use a finish coat color that matches chip number 25183 (cyan -blue ) of AMS -STD-595A for

weathered steel, unless otherwise specified in the contract.

6.When painting just beam ends of weathering steel, use a finish coat color that matches chip

number 30059 (Brown) of AMS -STD-595A, unless otherwise specified in the contract documents.

7.Match the color and gloss of the touch up finish coat on existing steel to the existing finish coat.
B.Provide expendable abrasives that meet SSPC -AB 1 and recyclable abrasives that meet SSPC -AB 3.

616.3Construction.

616.3.1 Submittals.

A.Contractor’s / Subcontractor’s SSPC -QP Certification.
1.Submit certifications for contractors and subcontractors removing or applying paint in

accordance with SSPC -QP1 - Standard Procedure for Evaluating Qualifications of Painting Contractors: Field Application to Complex Structures.

2.Submit certifications for contractors and subcontractors when the paint is being removed by

abrasive blast cleaning in accordance with SSPC -QP2, Category A - Standard Procedure for Evaluating Qualifications of Painting Contractors to Remove Hazardous Pa int.

3.Provide certificates that are effective prior to award of contract and remain in effect for the

duration of the contract.

Source: Delaware Standard Specifications for Road and Bridge Construction, 2025 Edition. Pages 279294 of 779.